Hydronic heater

ABSTRACT

An apparatus for heating a hydronic heating fluid comprising a casing body having an inlet and an outlet adjacent to the inlet and a fluid flow path between the inlet and outlets. The flow path extends along first and second substantially straight sections with a return bend therebetween. The apparatus further includes a heating element located within one of the first or second sections of the flow path. The second end may include a threaded heater bore aligned with the second section wherein the heating element is threadably insertable into the second section through the heater bore. The first end may include a pump in fluidic communication with the inlet, the pump being operable to draw the heating fluid in through the inlet and to discharge the heating fluid through the first section of the casing body.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates generally to hydronic heating systems in general and in particular to an apparatus for providing a modular localized hydronic heating supply.

2. Description of Related Art

Hydronic heating is a common heating system primarily used for heating floors, although walls and ceilings may also be heated. It is known that the systems used within the field of hydronic, may be complicated and expensive and are commonly required to be installed by qualified and skilled professionals.

Installation of hydronic heating systems within buildings, whether during initial construction or afterwards as a retrofit during renovations and remodeling has been historically very time consuming as well as entailing a lot of skilled labour. In particular, the boiler, controls and distribution systems are generally installed in one location such as in a basement or dedicated mechanical room. A network of fluid distribution pipes must then be routed throughout the buildings floors, walls and ceilings to the locations where the heat is desired.

Difficulties with such routing of piping and the like includes the possibility that the routing of the pipes or fluid conduits through the building walls, floors and ceilings to their destination point may put the piping in a place of potential damage. Additionally thermostats need to be routed from each of the rooms being serviced back to the system controls. For example, a nail or screw may be forced through the structural material and puncture the pipe. This creates potential for such damage to be caused in locations that cannot be accessed or seen. This may lead to great cost to the owner and or potentially the contractors involved.

Additionally, central hydronic heating systems also suffer from inefficiencies due to the distributed design of such system. In particular, heat is lost from the piping while the heating fluid is being transported to and from the location requiring the heat. This heat loss may be in locations where heat is not required and therefore heat energy is wasted. The energy required by the pump to circulate the fluid through the network of distribution tubing can also result in waste of energy.

Distributed systems also require a large amount of space at some location within the building for the heater, storage tank and associated hardware. It will be appreciated that the need to keep large volumes of water heated and kept at a relatively high temperature even when no heat is required to respond to any future demands contributing an additional waste of energy. Inevitably some of this heat will dissipate through a system's insulation (if there is any) and generally overheat the space in which the function is taking place. In addition, when fossil fuel type heating systems are used the heat given off from flue gasses into the flue pipe system is wasted heat. All of these losses can be classified as parasitic losses in the standard system designs which reduces the efficiency and thereby the effectiveness of such systems.

Additionally, attempts to renovate an existing building to include in-floor heating via hydronics have created additional difficulties. Within an existing finished building, such renovations typically requires cutting into walls floors and ceilings of building to rout the distribution pipe work. All of which requires repair and renewal after the piping has been installed.

SUMMARY OF THE INVENTION

According to a first embodiment of the present invention there is disclosed an apparatus for heating a hydronic heating fluid comprising a casing body having an inlet and an outlet adjacent to the inlet and a fluid flow path between the inlet and outlets. The flow path extends along first and second substantially straight sections with a return bend therebetween. The apparatus further includes a heating element located within one of the first or second sections of the flow path.

The first and second straight sections may be substantially parallel to each other. The first and second straight sections may extend substantially horizontal. The casing may extend between first and second ends wherein the inlet and outlet are located at the first end and the return bend is located at the second end.

The second end may include a heater bore aligned with the second section wherein the heating element is securable within the second section through the heater bore. The second section may include a heat sensor. The heating element may be turned off in response to the heat sensor sensing a predetermined set temperature. The return bend may further include a fluid expansion chamber.

The first end may include a pump in fluidic communication with the inlet, the pump being operable to draw the heating fluid in through the inlet and to discharge the heating fluid through the first section of the casing body. The pump may comprise a centrifugal pump. The pump may have a central axis extending substantially parallel to the first and second sections of the casing body.

The inlet and outlet may extend substantially downwardly from the casing body proximate to the first end thereof. The inlet and outlet may be formed through a common leg extending from the casing body.

The apparatus may further comprise a distribution manifold having a riser engageable upon the downspout. The riser may include a supply conduit in fluidic communication with the outlet of the casing body and a return conduit in in fluidic communication with the inlet of the casing body. The supply and return conduits may be formed within a common tubular member.

The distribution manifold may include a supply connection in fluidic communication with the supply conduit operable to be connected to a supply line of a hydronic heating tube and a return connection in fluidic communication with return conduit operable to be connected to a return line of a hydronic heating tube

The first section may include a fill and release valve with a diverter valve therebetween. The first section may include at least one gauge operable to display a condition within the system.

The casing body may be formed of connectable first and second casing halves. The first and second casing halves may be secured to each other with fasteners.

Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view,

FIG. 1 is a perspective view of a hydronic heating system according to a first embodiment of the present invention.

FIG. 2 is a side elevation view of an apparatus for heating the hydronic fluid of the system of FIG. 1.

FIG. 3 is an exploded side elevation view of the apparatus of FIG. 2.

FIG. 4 is a cross sectional view of the apparatus of FIG. 2.

FIG. 5 is an exploded view of a pair of casing halves for forming the casing of the apparatus of FIG. 2.

FIG. 6 is a detailed exploded perspective view of one of the insert sleeves for the casing of FIG. 5.

FIG. 7 is a cross sectional view of the apparatus of FIG. 2 as taken along the line A-A.

FIG. 8 is a top plan view of the header of the apparatus of FIG. 2.

FIG. 7 is a detailed exploded view of the casing of FIG. 5 showing the dividing plate.

DETAILED DESCRIPTION

Referring to FIGS. 1 through 9, a hydronic heating system is illustrated for providing heat eating to at least one in floor radiant heating loop 14. The system includes an apparatus 20 for heating the hydronic heating fluid and may be located under a cover 19, within a baseboard 18 or within a wall (as illustrated in FIG. 2) between adjacent wall studs 16 of a room.

With reference to FIGS. 2 through 9, the apparatus 20 comprises a casing body 22 having an inlet port 28 and an outlet port 29 extending therethrough.

The casing body 22 comprises a unitary body extending between first and second ends, 24 and 26, respectively. The inlet port 28 and outlet port 29 extend through a bottom of the casing body 22 proximate to the first end 24 and are adapted to introduce and remove the heating fluid from the casing body 22 as will be more fully described below.

The casing body 22 defines a flow path 30 extending along a top or first flow section 32 and returning along a bottom or second flow section 34 with a return bend 36 located therebetween. As illustrated, the casing body 22 may be formed of a pair of substantially parallel top and bottom tubular bodies, 38 and 40, respectively each containing and defining the first or second flow sections 32 and 34. Optionally, the casing body may comprise a unitary body of any desired shape.

As illustrated in FIG. 4, the casing body 20 includes a plurality of ports 42 extending through the wall thereof. Each port 42 is adapted to pass a component of the heating control system as are commonly known in the art. By way of non-limiting example, such components may comprise a make-up valve 44, a release valve 46, a pressure relief valve 50, a pressure or temperature gauge 45 and an air bleed valve 48 as are all commonly known. Each of the above system components is sealably secured within the port 42, by any commonly known means, such as, by way of non-limiting example, threading, bolting flanges, adhesives, welding, soldering, braising, or the like.

Additionally, the size and type of each port 42 will be selected to correspond to the size and type of each component which is intended to be located at such location. It will be appreciated that each of the above system components may also be located at different places along the casing body as desired by a user.

The top tubular body 38 may also include a diverter valve 52 located between the make-up and release valves 46 and 44 which is operable to divert the flow of fluid out of the apparatus 20 through the release valve 46 for collection by an external system (not shown) and to introduce a fluid flow in through the make-up valve 44 from such external system. Such diversion may be useful for exchanging or adding heating fluid to the apparatus as needed from time to time. The apparatus 20 may also include a fluid expansion chamber 54 adapted to receive an extra quantity of the heating fluid above the capacity of the heating system utilizing the apparatus 20. Examples of such expansion chamber, valves, pressure release valve and air bleed valve are well known in the art. As illustrated, the fluid expansion chamber 54 may include an expandable bladder 86 adapted to receive such extra fluid.

As illustrated in FIG. 3, the first end 24 of the casing includes a mounting flange 60 having a suction bore 62 therethrough in fluidic communication with the inlet port 28 of the casing. The flange 60 is adapted to receive a pump 64 thereon so as to located an impeller 66 on the pump 64 within the suction bore 62. The first end 24 additionally includes a discharge bore 68 extending therethrough in fluidic communication with the first flow section 32. The pump may be driven by any suitable motor type, such as, by way of non-limiting example, electric and is adapted to draw the heating fluid through the suction bore 62 and discharge it through the discharge bore 68 so as to create a fluid flow through the apparatus. As illustrated, the impeller may be a centrifugal type pump having an axis 65 extending substantially parallel to the first and second tubular bodies 38 and 40 although it will be appreciated that other pump types may be utilized as well, such as by way of non-limiting example screw, gear or reciprocating. Any commonly known pump mounting method, may be utilized, such as, by way of non-limiting example, flanges, threaded bores or clamping rings. In other embodiments, it will also be appreciated that the pump 64 may be located externally to the casing body 22 such that the suction bore 62 is in direct fluidic communication with the discharge bore 68. In other embodiments, the pump may be of a reversible type so as to permit the flow through the casing body 22 to be reversed.

The second end 26 of the casing body 22 includes a heater bore 70 extending therethrough with a heater mounting flange 72 located therearound. A heater 74 is provided with a mounting plate 76 adapted to sealably engage the heater and heater mounting plate on the heater mounting flange, such as, by way of bolting, threading, adhesives, gaskets or the like. The heater 74 may be of any suitable type, such as, by way of non-limiting example, an electric heating element as illustrated. The heater 74 will be selected to have a capacity corresponding to the heating needs of the room to be heated and may be of an electric resistance type as are commonly known.

With reference to FIG. 4, the heating fluid enters the apparatus through the inlet port 28. The pump impeller 66 draws the heating fluid through the suction bore 62 and discharges it through the discharge bore 68 whereafter it flows through the first flow section 32 of the casing body 22. At the end of the first flow section 32, the heating fluid is passed through an expansion chamber 78 wherein air entrained within the fluid and system has an ability to rise and separate from the rest of the fluid. Above the expansion chamber 78 and in communication with it may be mounted an automatic air bleed device 48 as are commonly known which may function to assist in the elimination of air from the system. As the heating fluid passes through the second flow section 34, it is heated by the heater 74 before passing through the discharge bore 68 and into the outlet port 29 and then out of the apparatus.

As illustrated in FIG. 1, the apparatus may have a control module 80 associated therewith as are commonly known. The control module 80 may be of any conventionally known type, such as mechanical, electronic, or central building control systems. The control module 80 has a room thermostat 82 of any suitable type, such as, by way of non-limiting example, mechanical or electrical sensors, electronic sensors or thermocouples located and adapted to sense the temperature of the room to be heated. The control module 80 also includes a water temperature sensor 84 of any suitable type located within or on an exterior surface of the casing body 22. The control module 80 controls the operation of the pump 64 and heater 74 to maintain the desired room temperature. In particular, the pump 64 may be programmed to run continuously during heating periods or seasons or during the entire year. When the room thermostat 82 determines that the room needs more heat, the control module energizes or otherwise turns on the heater 74 until the room thermostat has determined that an appropriate temperature in the room has been reached. During this time, the water temperature sensor 84 monitors the fluid temperature within the casing against a predetermined high temperature set point. When the high temperature set point has been reached, the control module 80 causes the heater to become de-energized, or otherwise turned off until the heating fluid has returned below the hi temperature set point. The high temperature set point may be selected depending upon the materials used in the casing as well as the heating tubes and other associated components. By way of non-limiting example, it has been found that a temperature of between 90 and 140 degrees has been useful.

The casing body 22 may be formed of any suitable material, such as, by way of non-limiting example, plastic, composite materials or metal, including steel, copper, stainless steel, aluminium, or iron. The casing body 22 may be formed by any conventionally known process including machining, welding, soldering adhering or braising separate components together. The casing body 22 may also be formed by casting, moulding or any other suitable process. In particular, the casing body 22 may be formed of first and second casing halves 90 and 92 which may be bolted adhered or otherwise connected to each other to form the completed casing body 22.

With reference to FIG. 5, the casing halves 90 and 92 may include mounting flanges 93 extending from a peripheral edge thereof having mounting bores 94 therethrough. The first and second casing halves 90 and 92 may be secured to each other by passing bolts 96 or other suitable fasteners through the mounting bores 94 to engage with corresponding nuts 98. The first and second casing halves 90 and 92 may also include a gasket 100, seal, caulking or any other suitable sealing member located therebetween. As illustrated, a dividing plate 102 may be provide in one or both of the first and second casing halves 90 and 92 to divide the inlet port 28 from the outlet port 29 of the casing as will be more fully described below.

Turning now to FIG. 9, each of the first and second casing halves 90 and 92 may include a notch 104 extending around the inlet and outlet ports 28 and 29. The notch 104 has a shape and size corresponding to the diverting plate 102 such that the diverter plate may be located therein and engaged within the notch 104 of each casing half. As illustrated, the inlet and outlet ports 28 and 29 may be formed within a common tubular member 108 having a dividing plate 102 therebetween to separate the inlet and outlet ports 28 and 29 from each other. It will be appreciated that the although diverting plate 102 is illustrated as being a separate member, it may also be formed with one of the casing halves or formed entirely with both such that the two diverter plates overlap and abut against each other. It will also be appreciated that the diverting plate 102 may be sealed within the notch 104 although a limited amount of heating fluid leaking past the dividing plate is acceptable as such leaked fluid will merely recirculate through the casing body and not escape from the overall system.

Turning now to FIG. 6, an assembly for threading system components into a split casing apparatus is illustrated. In such embodiments where the casing body 22 is formed by first and second casing halves 90 and 92, the ports 42 will similarly be formed of first and second port halves, 110 and 112, respectively. Each port half 112 and 112 may include a groove ring 114 adapted to receive an o-ring 116 or other suitable seal. The port will also include a port body 118 comprising a substantially ring-shaped body having a flange 124 adapted to be received within a second mating groove 126 within the port halves 110 and 112. The flange 124 and the second grooves 126 within both halves 110 and 112 of the port 42 may be formed in such a way as to resist any rotation of the port body 118 within the port 42 such as having a square, irregular, or keyed shape. The port body 118 also includes a central bore 122 therethrough which may be threaded or have any other surface treatments to be adapted to be engaged with the system components discussed above. In operation, the flange 124 of the port body may be placed within the second grooves 126 of the port halves 110 and 112 as the first and second casing halves 90 and 92 are drawn together by the bolts 96 and nuts 98 or other suitable securing method or device.

The apparatus 20 may also include a manifold 130 for distributing the heating fluid to and from the casing body 22. The manifold comprises a riser 131 and includes an inlet side 132 and an outlet side 134 separated by a center wall 106 and one or more water distribution tubes 136 extending therefrom. The inlet and outlet sides 132 and 134 are separated from each other so as to sealably connect with the inlet and outlet ports 28 and 29 of the casing body wherein the center wall will align with the dividing plate 102. Each of the manifold 130 and common tubular member 108 may include a flange, 109 and 138, respectively for clamping together according to any known means, such as bolts, adhesives, welding, braising or clamp rings 140. It will be appreciated that providing the casing body separate from the manifold permits simple heater and component exchange and maintenance without cutting into plumbing tubes. This will be especially useful when the system is mounted within a wall. As illustrated in FIGS. 2 through 9, the manifold 130 may also include valves 142 on each of the inlet and outlet sides 132 and 134 for each zone of the heating system. Such valves will permit purging of each loop by closing off the other when filling and draining . Additionally such valves gives control over the flow rate in each loop by restricting flow to one zone or the other

As described above, the apparatus 20 provides a localized heat source for hydronic heating systems. The system, provides a compact footprint by running the required flow through the system in parallel to itself thereby minimizing the overall length required. In particular, for many applications, the apparatus may have a length of less than 24 inches thereby permitting the apparatus 20 to be located between wall studs with no modification thereto. Accordingly, the apparatus may be further recessed into the wall interior reducing any special impacts on the room. The apparatus 20 may also be located and mounted within a room by any other conventionally known means, such as wall mounted brackets, covering with a base board or the like. By providing the heating source at the location where the heat is to be required, it will also be appreciated, that any excess heat which is transmitted through the casing body or associated components of the system is not wasted, as such heat will be utilized by the room to achieve the desired temperature, thus increasing efficiency over conventional designs.

While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims. 

What is claimed is:
 1. An apparatus for heating a hydronic heating fluid comprising: a casing body having an inlet and an outlet adjacent to 1 inlet and a fluid flow path between said inlet and outlets, wherein said flow path extends along first and second substantially straight sections with a return bend therebetween; and a heating element located within one of said first or second sections of said flow path.
 2. The apparatus of claim 1 wherein said first and second straight sections are substantially parallel to each other.
 3. The apparatus of claim 2 wherein said first and second straight sections extend substantially horizontal.
 4. The apparatus of claim 3 wherein said casing extends between first and second ends wherein said inlet and outlet are located at said first end and said return bend is located at said second end.
 5. The apparatus of claim 4 wherein said second end includes a heater bore aligned with said second section wherein said heating element is securable within said second section through said heater bore.
 6. The apparatus of claim 5 wherein said second section includes a heat sensor.
 7. The apparatus of claim 6 wherein said heating element is turned off in response to said heat sensor sensing a predetermined set temperature.
 8. The apparatus of claim 1 wherein said return bend further includes a fluid expansion chamber.
 9. The apparatus of claim 1 wherein said return bend further includes a an air separator.
 10. The apparatus of claim 9 wherein said air separator extends from a topmost portion of said casing body.
 11. The apparatus of claim 1 wherein said first end includes a pump in fluidic communication with said inlet, said pump being operable to draw said heating fluid in through said inlet and to discharge said heating fluid through said first section of said casing body.
 12. The apparatus of claim 1 wherein said inlet and outlet extend substantially downwardly from said casing body proximate to said first end thereof.
 13. The apparatus of claim 12 wherein said inlet and outlet are formed through a common leg extending from said casing body.
 14. The apparatus of claim 13 further comprising a distribution manifold having a riser engageable upon said downspout.
 15. The apparatus of claim 14 wherein said riser includes a supply conduit in fluidic communication with said outlet of said casing body and a return conduit in in fluidic communication with said inlet of said casing body.
 16. The apparatus of claim 15 wherein said supply and return conduits are formed within a common tubular member.
 17. The apparatus of claim 15 wherein said distribution manifold includes a supply connection in fluidic communication with said supply conduit operable to be connected to a supply line of a hydronic heating tube and a return connection in fluidic communication with return conduit operable to be connected to a return line of a hydronic heating tube
 18. The apparatus of claim 1 wherein said first section includes a fill and release valve with a diverter valve therebetween.
 19. The apparatus of claim 1 wherein said first section includes a gauge operable to indicate at least one condition of a fluid therein.
 20. The apparatus of claim 1 wherein said casing body is formed of connectable first and second casing halves.
 21. The apparatus of claim 20 wherein said first and second casing halves are secured to each other with fasteners.
 22. The apparatus of claim 20 wherein said first and second casing halves are sealed to each other with a sealing member. 